Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Instruction - page 10
2A-24
Chapter 2 Part A Four-cylinder engines
15.5 Match-mark the position of the driveplate and backing plate
15.6 Remove the driveplate from the crankshaft
to the crankshaft and using an appropriate
tool to hold the driveplate, remove the bolts
2
Remove the transaxle assembly (see
Chapter 7).
3
On vehicles equipped with a manual
transaxle,
now is a good time to
check/replace the modular clutch assembly
(see Chapter 8).
4
To ensure correct alignment during rein-
stallation, match-mark the driveplate and
backing plate to the crankshaft so they can
be reassembled in the same position.
5
Remove the bolts that secure the fly-
wheel or driveplate to the crankshaft (see
illustration). A special tool is available a most
auto parts stores to hold the driveplate while
loosening the bolts, if the tool is not available
wedge a screwdriver in the starter ring gear
teeth to jam the driveplate.
6
Remove the driveplate from the
crankshaft (see illustration).
7
Clean the driveplate to remove any
grease and oil. Inspect it for cracks, distortion
and missing or excessively worn ring gear
teeth. Replace if necessary.
8
Clean and inspect the mating surfaces
of the driveplate and the crankshaft.
9
If the crankshaft rear main seal is leak-
ing, replace it before reinstalling the drive-
plate (see Section 16).
Installation
10
Position the driveplate and backing
plate against the crankshaft. Align the previ-
ously applied match marks. Before installing
the bolts, apply thread locking compound to
the threads.
11
Hold the driveplate with the special
holding tool, or wedge a screwdriver in the
starter ring gear teeth to keep the driveplate
from turning. Tighten the bolts to the torque
li sted in this Chapter's Specifications.
12
The remaining installation steps are the
reverse of the removal.
16 Rear main oil seal - replacement
Refer to illustrations 16.3 and 16.5
1
The one-piece rear main oil seal is
pressed into a bore machined into the rear
main bearing cap and engine block.
2
Remove the transaxle, modular clutch
assembly (if equipped) and driveplate (see
Section 15).
3
Note: Observe that the oil seal is
installed flush with the outer surface of the
block. Pry out the old seal with a 3/16-inch
flat blade screwdriver (see illustration). Cau-
tion: To prevent an oil leak, be very careful
16.3 Using a 3/16 inch flat blade screwdriver, very carefully pry
the crankshaft rear main seal out of it's bore - DO NOT nick or
scratch the sealing surfaces on the crankshaft or seal bore
16.5 Position the new seal with the words THIS SIDE OUT facing
away from the rear of the engine. Install this seal DRY! DO NOT
lubricate! Gently and evenly drive the seal into the cylinder block
until it is FLUSH with the outer surface of the block. DO NOT drive
it past flush or there will be an oil leak - the seal must be FLUSH!
Chapter 2 Part A Four-cylinder engines
2A-25
TRANSMISSION
SUPPORT
ASSEMBLY
RIGHT ENGINE
SUPPORT
ASSEMBLY
LEFT
FRAME
FRAME
RAIL
RAIL
GROUND
CABLE
TRANSMISSION
TRANSMISSION
BRACKET
17.9a Typical left engine mount (passenger's side)
17.9b Typical right engine mount (driver's side)
2A
not to scratch or otherwise damage the
crankshaft sealing surface or the seal bore in
the engine block.
4
Clean the crankshaft and seal bore in
the block thoroughly and de-grease the areas
by wiping them with a rag soaked in lacquer
thinner or acetone. DO NOT lubricate the lip
or outer diameter of the new seal - it must be
installed as it comes from the manufacturer -
DRY.
5
Position
the
new seal onto the
crankshaft. Note: When installing the new
seal, if so marked, the words THIS
SIDE OUT
on the seal must face out, toward the rear of
the engine. Using an appropriate size driver
and pilot tool, drive the seal into the cylinder
block until it is flush with the outer surface of
the block. If the seal is driven in past flush,
there will be an oil leak. Check that the seal is
flush (see illustration).
6
The remaining installation steps are the
reverse of removal.
17
Engine mounts - check and
replacement
1
Engine mounts seldom require atten-
tion, but broken or deteriorated mounts
should be replaced immediately or the added
strain placed on the driveline components
may cause damage or accelerated wear.
Check
2
During the check, the engine must be
raised slightly to remove the weight from the
mounts.
3
Raise the vehicle and support it securely
on jackstands, then position a jack under the
engine oil pan. Place a large wood block
between the jack head and the oil pan to pre-
vent oil pan damage, then carefully raise the
engine just enough to take the weight off the
mounts. Warning:
DO NOT
place any part of
your body under the engine when it's sup -
ported only by a jack!
4
Check the mounts to see if the rubber is
cracked, hardened or separated from the
metal backing. Sometimes the rubber will
split right down the center.
5
Check for relative movement between
the mount plates and the engine or frame
(use a large screwdriver or pry bar to attempt
to move the mounts). If movement is noted,
lower the engine and tighten the mount fas-
teners.
6
Rubber preservative may be applied to
the mounts to help slow deterioration.
Replacement
Refer to illustrations 17.9a, 17.9b, 17.9c,
17.9d, 17.9e and 17.9f
7
Raise the front of the vehicle and sup-
port it securely on jackstands.
8
Place a floor jack under the engine (with
a wood block between the jack head and oil
pan) and raise the engine slightly to relieve
17.9c Typical front engine mount
2A-26
Chapter 2 Part A Four-cylinder engines
17.9d Typical engine support module (front and rear
lower mounts - 1995 through 1997 models)
17.9f Typical 2.4L rear engine mount
the weight from the mounts. Note: On 1995 to
condenser (if equipped)
must
be
supported.
engine/transaxle removal.
1997 models, the front engine mount (engine
9
Remove the fasteners and detach the
10 Installation is the reverse of removal.
support module) is
attached
to the lower radi-
mount from the frame and engine (see illus-
Use thread locking compound on the mount-
ator support.
When
removing the engine sup-
trations). Caution: Do not disconnect more
ing bolts and be sure to tighten them
port module, the radiator
and
air conditioning
than one mount at a time, except during
securely.
LOWER RADIATOR
SUPPORT
FRONT
ENGINE MOUNT
DAMPER WEIGHT
(SOME MODELS)
ENGINE
SUPPORT MODULE
REAR STRUT
REAR
BRACKET
ENGINE MOUNT
SUPPORT BRACKET
(SOME MODELS)
17.9e Typical 2.0L rear engine mount
Chapter 2 Part B
V6 engine
Contents
Section
Camshafts - removal, inspection and installation ................................10
Camshaft oil seal - replacement ............................................................8
CHECK ENGINE light ........................................................See Chapter 6
Crankshaft front oil seal - replacement ..................................................7
Cylinder head - removal and installation ..............................................12
Engine mounts - check and replacement ............................................17
Exhaust manifold - removal and installation ..........................................5
Driveplate - removal and installation ....................................................15
General information................................................................................1
Intake manifold ...................................................................................... 4
Section
Oil pan - removal and installation ........................................................ 13
Oil pump - removal, inspection and installation ...................................14
Rear main oil seal - replacement......................................................... 16
Repair operations possible with the engine in the vehicle .....................2
Rocker arm and hydraulic valve lash adjuster
assembly - removal, inspection and installation .............................. 9
Timing belt - removal, inspection and installation ................................. 6
Top dead center (TDC) for number one piston .............. See Chapter 2C
Valve cover - removal and installation................................................... 3
Valve springs, retainers and seals - replacement ................................ 11
2B
Specifications
General
Bore .........................................................................................................
Stroke......................................................................................................
Displacement...........................................................................................
Firing order..............................................................................................
Compression ratio...................................................................................
Compression pressure ............................................................................
Oil pressure
At idle speed......................................................................................
At 3000 rpm........................................................................................
Camshaft
Endplay
Standard.............................................................................................
Service limit ........................................................................................
Cylinder head
Cylinder head gasket surface warpage limit...........................................
Intake and exhaust manifolds
Intake manifold warpage limit.................................................................
Exhaust manifold warpage limit..............................................................
3.29 inches
2.992 inches
152 cubic inches (2.5 liters)
1-2-3-4-5-6
9.4:1
178 psi @ 250 rpm
6 psi (minimum)
35 to 75 psi
0.004 to 0.008 inch
0.0016 inch
0.008 inch
0.008 inch
0.012 inch
Cylinder numbering
and spark plug wire
terminal locations
5
3
1
FRONT OF VEHICLE
2B-2
Chapter 2 Part B V6 engine
Oil pump
Inner rotor-to-outer rotor lobe clearance .........................................................0.003 to 0.007 inch
Outer rotor-to-housing clearance
Standard .....................................................................................................0.004 to 0.007 inch
Service limit................................................................................................ 0.0138 inch
Rotor-to-cover clearance (end clearance)....................................................... 0.0015 to 0.0035 inch
Torque specifications
Ft-lbs (unless otherwise indicated)
Camshaft sprocket bolt ....................................................................................65
Camshaft thrust case bolts.............................................................................. 108 in-lbs
Crankshaft damper/pulley bolt .........................................................................134
Crankshaft rear main seal retainer bolts ..........................................................97 in-lbs
Cylinder head bolts..........................................................................................80
EGR tube bolts.................................................................................................95 in-lbs
Engine mounting bracket bolts........................................................................33
Exhaust manifold-to-cylinder head nuts..........................................................33
Exhaust manifold-to-exhaust pipe nuts...........................................................21
Exhaust manifold heat shield bolts ..................................................................115 in-lbs
Driveplate-to-crankshaft bolts ......................................................................... 70
Intake manifold
Upper intake manifold bolts........................................................................160 in-lbs
Lower intake manifold bolts........................................................................185 in-lbs
Oil filter adapter bolts.......................................................................................17
Oil pan bolts .....................................................................................................53 in-lbs
Oil pump
Attaching bolts
M8 bolts.................................................................................................10
M10 bolts.............................................................................................. 30
Cover bolts ................................................................................................. 88 in-lbs
Pick-up tube bolts...................................................................................... 168 in-lbs
Relief valve cap bolt................................................................................... 30
Rocker arm shaft bolts .....................................................................................23
Thermostat housing bolts................................................................................ 168 in-lbs
Timing belt
Cover bolts..................................................................................................105 in-lbs
Tensioner arm assembly bolt..................................................................... 33
Tensioner pulley bolt.................................................................................. 35
Valve cover bolts..............................................................................................88 in-lbs
Water pump mounting bolt.............................................................................. 17
"Refer to Part C for additional torque specifications
1
General information
This Part of Chapter 2 is devoted to in-
vehicle engine repair procedures. Information
concerning engine removal and installation
and engine block and cylinder head overhaul
can be found in Part C of this Chapter.
The following repair procedures are
based on the assumption that the engine is
installed in the vehicle. If the engine has been
removed from the vehicle and mounted on a
stand, many of the steps outlined in this Part
of Chapter 2 will not apply.
The Specifications included in this Part
of Chapter 2 apply only to the procedures
contained
in
this Part. Part C of Chapter 2
contains the Specifications necessary for
cylinder head and engine block rebuilding.
2
Repair operations possible with
the engine in the vehicle
Many major repair operations can be
accomplished without removing the engine
from the vehicle.
Clean the engine compartment and the
exterior of the engine with some type of
degreaser before any work is performed. It
will make the job easier and help keep dirt
out of the internal areas of the engine.
Depending on the components involved,
it may be helpful to remove the hood to
improve access to the engine as repairs are
performed (refer to Chapter 11 if necessary).
Cover the fenders to prevent damage to the
paint. Special pads are available, but an old
bedspread or blanket will also work.
If vacuum, exhaust, oil or coolant leaks
develop, indicating a need for gasket or seal
replacement, the repairs can generally be
made with the engine in the vehicle. The
intake and exhaust manifold gaskets, oil pan
gasket, camshaft and crankshaft oil seals
and cylinder head gasket are all accessible
with the engine in place.
Exterior engine components, such as
the intake and exhaust manifolds, the oil pan,
the oil pump, the water pump, the starter
motor, the alternator, the distributor and the
fuel system components can be removed for
repair with the engine in place.
Since the camshafts and cylinder head
can be removed without pulling the engine,
valve component servicing can also be
accomplished with the engine in the vehicle.
Replacement of the timing belt and sprockets
is also possible with the engine in the vehicle.
In extreme cases caused by a lack of
necessary equipment, repair or replacement
of piston rings, pistons, connecting rods and
rod bearings is possible with the engine in the
vehicle. However, this practice is not recom-
mended because of the cleaning and prepa-
ration work that must be done to the compo-
nents involved.
3
Valve cover - removal and
installation
Removal
Refer to illustrations 3.6 and 3.7
1
Disconnect the negative battery cable
from the ground stud on the left shock tower
(see Chapter 5, Section 1).
2
Remove the air cleaner assembly (see
Chapter 4).
Chapter 2 Part B V6 engine
2B-3
3.6 Valve cover mounting bolts (arrows)
3.7 Remove and replace the seal from each spark plug tube
3
If removing the rear valve cover (near
the firewall), remove the upper intake mani-
fold (see Section 4).
4
Clearly label then remove the spark plug
wires from the valve cover (see Chapter 1 if
necessary).
5
Clearly label and then disconnect any
emission hoses and electrical cables which
connect to or cross over the valve cover.
6
Remove the valve cover bolts and lift off
the cover (see illustration). If the cover
sticks to the cylinder head, tap on it with a
soft-face hammer or place a wood block
against the cover and tap on the wood with a
hammer. Caution: If you have to pry between
the valve cover and the cylinder head, be
extremely careful not to gouge or nick the
gasket surfaces of either part. A leak could
develop after reassembly.
7
Remove the spark plug tube seals. Even
if they look OK, they should be replaced (see
illustration).
8
Thoroughly clean the valve cover and
remove all traces of old gasket material. Gas-
ket removal solvents are available from auto
parts stores and may prove helpful. After
cleaning the surfaces, degrease them with a
rag soaked in lacquer thinner or acetone.
Installation
9
Install the new spark plug seals onto the
tubes.
10 Install a new gasket on the cover, using
anaerobic RTV sealant to hold it in place.
11
Tighten the valve cover bolts in 3 steps
to the torque listed in this Chapter's Specifi-
cations using a criss-cross pattern starting in
the middle of the cover and working out-
wards.
12
The remaining installation steps are the
reverse of removal. When complete, run the
engine and check for oil leaks.
Spark plug tube replacement
13
Remove the applicable valve cover (see
above).
14
Grasp spark plug tube with locking pli-
ers, carefully twist back and forth and remove
the tube from cylinder head.
15
Clean the locking agent from the tube
and the recess in cylinder head with solvent,
and dry thoroughly.
16
Apply a small amount of Loctite No.
271, or equivalent, around the lower end of
the tube and install the tube into the cylinder
head. Carefully tap the tube into the recess
with a wood block and mallet until it is fully
seated in the cylinder head.
4
Intake manifold - removal and
installation
Upper intake manifold
Removal
Refer to illustrations 4.3a, 4.3b, 4.5, 4.6, 4.7a
and 4.7b
1
Disconnect the negative battery cable
from the ground stud on the left shock tower
(see Chapter 5, Section 1).
2
Remove the air filter inlet duct from the
throttle body (see Chapter 4 if necessary).
3
Clearly label and disconnect all hoses,
wires, brackets and emission lines which
attach to the intake manifold (see illustra-
tions).
4
Disconnect the accelerator cable and
2B
4.3a Disconnect the throttle position sensor connector
4.3b Disconnect the purge vacuum hose from the throttle
body fitting
2B-4
Chapter 2 Part B V6 engine
LOWER INTAKE
MANIFOLD
GASKETS
GASKETS
NUT
4.5 Exploded view of V6 engine intake and exhaust system components
cruise control cable (if applicable) from the
throttle body (see Chapter 4 if necessary).
5
Remove the bolts securing the upper
intake manifold to the right and left side sup-
port brackets (see illustration).
6
Remove the EGR tube (see illustration).
7
Loosen the upper intake manifold bolts
in a criss-cross pattern 1/4 turn at a time until
they can be removed by hand. Remove the
upper intake manifold from the engine (see
illustrations). If it sticks, tap the manifold
with a soft-face hammer or carefully pry it
from the lower intake manifold. Caution: Do
not pry between gasket sealing surfaces.
8
To minimize the chance of gasket debris
or other contamination from getting into the
engine, place clean rags into the lower intake
manifold passages.
9
Remove all traces of gasket material
from both the upper and lower intake mani-
fold by carefully scraping them using a suit-
able gasket scraper. Caution: The intake
manifold components are made of aluminum
and are easily nicked or gouged. Do not dam -
age the gasket surfaces or a leak may result
after the work is complete. Gasket removal
solvents are available from auto parts stores
and may prove helpful.
10
Using a precision straightedge and
feeler gauge, check the upper and lower
intake manifold mating surfaces for warpage
(see illustration 4.22). If the warpage on any
surface exceeds the limits listed in this Chap-
ter's Specifications, the discrepant intake
manifold must be replaced or resurfaced by
an automotive machine shop.
4.7a Starting in the center and working outwards, remove the
upper intake manifold mounting bolts in a criss-cross pattern .. .
4.6 Remove the EGR tube
Chapter 2 Part B V6 engine
2B-5
4.7b ... then remove the manifold from the engine
4.22 Check the lower intake manifold gasket surface for warpage
Installation
11
Remove the rags from the lower intake
manifold. Use a shop vacuum to remove any
contamination that may be present.
12 Install the upper intake manifold, using a
new gasket. Tighten the bolts in 3 stages,
working from the center out, to the torque
li sted in this Chapter's Specifications.
13 Install the EGR tube using new gaskets.
Tighten the bolts to the torque listed in this
Chapter's Specifications.
14
The remaining installation steps are the
reverse of removal.
Lower intake manifold
Removal
Refer to illustration 4.22
15
Perform the fuel pressure relief proce-
dure (see Chapter 4).
16
Remove the upper intake manifold (see
above).
17
Remove the fuel rail and injector assem-
bly (see Chapter 4).
18
Loosen the intake manifold nuts in the
reverse order of the tightening sequence (see
illustration 4.24), 1/4 turn at a time until they
can be removed by hand. Remove the wash-
ers.
19
Remove the lower intake manifold from
the engine. If it sticks, tap the manifold with a
soft-face hammer or carefully pry it from the
heads. Caution: Do not pry between gasket
sealing surfaces.
20
To minimize the chance of gasket debris
or other contamination from getting into the
engine, place clean rags into the cylinder
head intake passages.
21
Remove all traces of gasket material from
the upper and lower intake manifold and cylin-
der heads by carefully scraping them using a
suitable gasket scraper. Caution: The intake
manifold components and cylinder heads are
made of aluminum and are easily nicked or
gouged. Do not damage the gasket surfaces or
a leak may result after the work is complete.
Gasket removal solvents are available from
auto parts stores and may prove helpful.
22
Using a precision straightedge and
feeler gauge, check the upper and lower
intake manifold gasket surfaces for warpage
(see illustration). Check the gasket surface
on the cylinder head also. If the warpage on
any surface exceeds the limits listed in this
Chapter's Specifications, the discrepant
component must be replaced or resurfaced
by an automotive machine shop.
Installation
Refer to illustration 4.24
23
Remove the rags from the cylinder head
intake passages. Use a shop vacuum to
remove any contamination that may be pre-
sent.
24 Install the lower intake manifold, using a
new gaskets. Tighten the nuts in three
stages, in the sequence shown (see illustra-
tion) to the torque listed in this Chapter's
Specifications.
25 Install the fuel rail (see Chapter 4).
26 Install the upper intake manifold, using a
new gasket. Tighten the bolts in three stages,
working from the center out, to the torque
li sted in this Chapter's Specifications.
27 Install the EGR tube using new gaskets.
Tighten the bolts to the torque listed in this
Chapter's Specifications.
28
The remaining installation steps are the
reverse of removal.
5
Exhaust manifold - removal and
installation
Warning: Allow the engine to cool completely
before beginning this procedure.
Note: This procedure can be used to remove
one or both of the exhaust manifolds as
required.
Removal
Refer to illustrations 5.3, 5.8 and 5.9
1
Disconnect the negative battery cable
from the ground stud on the left shock tower
(see Chapter 5, Section 1).
2
Raise the vehicle and support it securely
on jackstands.
3
Remove the exhaust manifold heat
shield(s) (see illustration). Before attempting
2B
4.24 Lower intake manifold nut tightening sequence
5.3 Exhaust manifold heat shield bolts (arrows) (front exhaust
manifold shown) - the upper alternator bracket must be removed
to extract the upper left heat shield bolt
